Fabric having pile raised over weft



Sept. 8, 1959 F. w. E. HOESELBARTH ,903,0

FABRIC HAVING PILE RAISED OVER WEFT 5 Sheets-Sheet 1 Filed Oct. 23. 1952 0 2 m Q 7,6,5 l I Sept. 8, 1959 F. w. E. HOESELBARTH 2,903,022

FABRIC HAVING PILE RAISED OVER WEFT Filed Oct. 23, 1952 s Sheets-Sheet 2 INVENT R 794222 1445 fioeaezzarfl.

Sept. 8, 1959 F. w. E. HOESELBARTH 2,903,022

FABRIC HAVING PILE RAISED OVERYWEFT 3 Sheets-Sheet 5 Filed 001;. 23, 1952 INVENTOR ATTORNEYS- United States Patent FABRIC HAVING PHJE RAISED OVER WEFT Frank W. E. Hoeselbarth, Carlisle, Pa., assignor, by mesne assignments, to Bigelow-Sanford Carpet Company, Inc., a corporation of Delaware ApplicationOctober 23, 1952, Serial No. 316,367

' Claims. or. 139-406) the preferred embodiment more than or is unusually. thick and also varying in thickness along its length. A further purpose is to place the high pile formed over the wires and the low pile formed over the special face weft in the same transverse row and to determine which ends are to form a high pile and which ends are to form a low pile by a pattern control such as a jacquard mechanism.

A further purpose is to produce a velvet carpet by plac- 1 ing the high pile formed over the wires and the low pile formed over the special weft in adjoining transverse rows. A furtherpurpose is to employ a face weft having a thickness between one-eighth and one-quarter inch.

A further purpose is to utilize a face weft varying in thickness and having a thickness of between one-eighth and one-quarter inch at thick places and between one-t sixth and one-eighth inch at thin places.

A further purpose is to raise certain pile warp ends in a particular transverse row overwires, to insert a face weft in the same row in front of the stnffer warp and behind a binder warp and preferably the only binder warp, using the face weft to raise the rejected pile warp ends in pile loops by virtue of unusual thickness of the face weft, variation in thickness of the face weft, or both unusual thickness and variation in thickness.

.Further purposes appear in the specification and in the claims.

in the drawings I have chosen to illustrate a few only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation, and clear demonstration of the principles involved.

Figure l is a standard warpwise weave diagram showing a preferred embodiment of the weave of the invention.

Figure 2 is an enlarged section of Figure l on the line Z2 omitting wires and showing only the ends in the plane of the section, the pile being lower in proportion.

Figures 3, 4; 5, 8 and 9 are views corresponding to Figure '1 showing variations.

Figure 6 is an enlarged fragmentary side elevation of one face weft which may be employed in the invention.

Figure 7 is an enlarged fragmentary side elevation of a variant face weft which may be employed.

Describing in illustration but not in limitation and referring to the drawing.

It has been very desirable to obtain texture effects, hav-.

ing high and low pile in the same transverse row, or in adjoining transverse rows in carpets and rugs.

Rodie'r German Patent No. 269,285,, dated January 16, 1914, describes pile carpet weaving by inserting trans- 1 shed).

verse elements of cotton or the like which vary in thick ness and raise the pile, and removing the same from the fabric by chemical treatment before use. No Wires are inserted and pulled laterally.

The present invention is intended to produce texturing by a combination of metallic wires of the character usually employed in transverse wire weaving, and wefts left in the finished fabric which are unusual in respect either to their thickness or their variation in thickness or both characteristics. The wefts will likewise in some cases be colored as part of a pattern effect and show through at the front of the fabric in gaps in the pile. Of course there will permissibly be several colors of wefts in a multiple shuttle loom. The pile projections raised over the wires and the special wefts may appear in the same transverse row or in different transverse rows, and where they appear in the same transverse row the high pile raised over the wire will be selected by a pattern control. The low pile created by the special face wefts will in some cases be of uniform height and in other cases will vary in height in the same transverse row.

In Figure 1 I illustrate a weave in accordance with the invention, which shows both Wilton or brussels and velvet or tapestry carpet weaves in accordance with the invention. Assuming first that a velvet or tapestry Weave is being made, and beginning at the first wire position at the left in Figure 1, pile warp 20 is fully raised and single binder warp 21 is raised half way, forming an upper shed, and stufi'er warp 22 is lowered forming a lower shed. A pile wire 23 is inserted in the upper shed, which will be any of the usual characters of pile wire, whether cutting or non-cutting, relatively high or low, straight or wavy (having high and low portions along its length within the shed) or of flag type (with an abnormally high non-cutting portion at the end remote from the head beyond the The invention is applicable to make out pile fabrics.

In the lower shed a front or face weft 24 is inserted, which in one form as shown in Figure 6 is a weft of uniform thickness but abnormally great thickness, having a thickness in the range between Ma and 4 inch. In the preferred embodiment of the invention, however, the front weft as shown in Figure 7 and in Figure 2 varies markedly in thickness along its length, as indicated at 24, having thick portions 25 between A3 and 4 inch and thin portions 26 of thickness between A and /s inch (the variation in thickness along the length of the front weft will preferably be more than 25%).

At the next step in weaving proceeding toward the right in Figure l, stuffer warp 22 is raised half way and all other warps are lowered, forming a lower shed into which back weft 27 (behind the stuffer warp) is inserted, while it will be understood that the back weft will in the broadest aspects of the invention, as later explained more in detail, be either identical with the front weft or smaller in thickness than the front weft. In the preferred embodiment of the invention the back weft is a thin weft whereas the front weft is thick and variant in thickness.

At the next step of the Weave toward the right in Figure 1, all ends of pile warp 20 are raised half way, binder warp 21 is raised half way and stutter Warp 22 is lowered, forming a lower shed in which a shot of face weft 24 is inserted of the character shown in Figures 6 or 7. At this step in a velvet or tapestry carpet weave no pile is raised over the wire and the wire will optionally be omitted.

At the next step to the right the back weft is inserted as previously described, and so the Weave repeats according to any predetermined sequence.

At the next face weft in the form shown, the pile is raised over the front.

dent that in velvet and tapestry weaving the choice as to whether transverse rows or high pile over wires and low pile over face wefts alternate, or whether two or more of one adjoin before one, two or more rows of the other are encountered, is a matter .of pattern design.

In many instances the weave ofFigure 1 will be applied using a jacquard mechanism or other pattern control, in which case there will be selected pile warp ends 20' (Figure 2) raised over wires at each front weft position in relatively 'high pilesubstantially above the front weft, and also low pile loops 20 raised directly over front wefts 24 in .the same transverse row. When viewed in this light, Figure 1 shows the situation at one pile warp end position, the 1st, 4th and 5th front weft positions from the left showing the selection of the pile warp end by the jacquard mechanism and the 2nd and 3rd front weft positions showing the rejected pile warp end forming low pile .directly over the front weft. Thus in each of these front weft positions there are selected high pile projections in front of and behind the plane ofthe paper and rejected low pile loops in front of and behind the plane of the paper, according to the pattern control.

In some cases it is preferred to use two binder warps, and in Figure 3 I show an additional binder warp 21, and additional front and back wefts woven between this additional binder warp and the stufrer warp. This weave is through to the back, an optional feature which may be applied in the invention. Thus interpreting Figure 3, in the left hand wire position the pile warp 20 is fully raised and binder warp 2-1 is raised half way forming an upper shed (and if a jacquardrnechanism is used rejected pile warp ends not shown are raised half way), while stuifer warp 22 and binder warp 21' are lowered forming a' lower shed. A wire 23 is inserted in the upper shed and a face weft 24 is inserted in the lower shed. In the next step binder warp 21 is lowered and all other warps are raised half way, and back weft 27 is inserted in the lower shed thus formed.

In the next step binder warp 21' is raised half way and all other warps are lowered, forming a lower shed into which face weft 24 is inserted. In the next step stuffer warp 22 is raised half way and all other warps arelowered, forming a lower shed in which back weft 27 is inserted.

The weaving then proceeds as before, at the next weft position pile warp 2i) being raised half way (and if a jacquard mechanism is used certain ends not shown in this position also being fully raised over the wire), binder warp 21 being raised half way, and stulfer warp 22 and binder warp 21 being lowered forming a lower shed in which face weft 24 is inserted. '(If an upper shed is formed, a wire is also inserted in an upper shed.) Subsequent operations proceed as described in previous steps, the pile warp end being raised over the face weft in the 9th step and over the wires in the 13th and 17th steps.

The invention will in many cases be employed using a pattern control mechanism such as a jacquard and using two or more pile warps. In the forms shown in Figures 4 and 5, pile warp 20 and pile warp 20 are employed, along with binder warps 21 and 21 and stuifer warp 22. In this case both the front or face wefts 24 and the back wefts 27 come from the same shuttle box and both are of the character shown in Figure 6 or Figure 7. Figure 5 is similar except that the front or face wefts 24 are of the special character and the back wefts 27 are thin wefts drawn from another shuttle box.

Considering the weaves of Figures 4 and 5, in the left hand position shown, the rejected ends of pile warp 20 are raised half way with binder warp 21 while pile warp 20 stulfer warp 22 and binder Warp 21' are lowered forming a lower shed into which face weft 24 is inserted. There is also at other dent positions an upper shed not shown at this position formed by the selected ends of .pile

4 other warps are raised half way, forming a lower shed at which hack weft 27 is inserted.

In the next step the rejected ends of pile warp 20 are raised half way along with binder warp 21' (the selected ends of pile warp 20 not shownbeing fully raised) and all other warps are lowered forming a lower shed into which face weft 24 is inserted.

The fourth step is identical with the second step. The fifth step is identical with the first step. The sixth step is identical with the second step. The seventh step is identical with the third step. The eighth step is identical with the second step.

In the ninth step the selected ends of pile warp 20 are shown fully raised over the wire 23, while binder warp 21' is raised half way and all other warps are lowered forming a lower shed. The wire is inserted in the upper shed and a front weft is inserted in the lower shed.

The tenth step is the same as the second step. The eleventh step differs from previous steps shown because pile warp 20 instead of being carried under the wire and over the face weft to form low pile is here rejected, beingcarried down with the stuifer warp, with binder warp 21 and with pile warp 20, while binder warp 21' at this point is raised half way before the shot of weft is inserted.

Figures 8 and 9 show velvet or tapestry carpet weaves to which the invention has beenapplied, Figure ,8 showing a V weave and Figure 9 a W- weave. Analyzing Figure 8:

.Step 1, beginningat theleft, pile warp 20 fully raised,,

binder warp 21 raised half way, forming an upper, shed. All 'otherwarpslowered, forming a lower shed. Wire 23 inserted in upper shed, face weft 24 inserted in lower shed.

Step 2, binder warp 21' lowered, all other warpsraised half way, forming lower shed. Back weft 27 inserted;

Step 9 pile warp 20 and binder warp 21 raised half. way, forminglower shed. Face weft 24 inserted in lower.

shed. Wire 23, if inserted,,performs no function .here.

Step 10 same as step 2. Step 11, pile warp 20 fully raised, binder warp 21' raised half way, forming an upper shed. All other warps lowered, forming a lowershed. Wire 23 inserted in upper shed, face weft 24 inserted inllowerlshed.

Step 12. same as vstep 4.

Step 13 same as step 9.

Step 14 same as step .2.

Step'15 same as step 1.1.

Step 16 same as step 4.

Step 17 same as step 1.

Step 18 same as step 2.

In, Figure 8 the wires are noncutting. Figure 9 employs cutting wires. It may be analyzed asv follows:

Step 1, starting from the left, pile warp 20 fully raised, pile warp 20 and :binder warp .21 raised half way, forming an upper shed. Stulfer warp 22 is lowered, forming a lower shed. Wire 23 is inserted in upper shed, and face weft 24 is inserted in lower shed. I

Step2, stuffer warp 22 raised halfway, all other warps lowered, forming a lower shed. Back weft 27 is inserted in. lower shed.

Step 3, pile warps 20 and 20 and binder warp 21 raised half way, stuifer warp 22.1owered forming a lower shed. Wire 23, if inserted at all, is not operative. V

Step z t-same as step 2.

Step5 same as step 1.

' Step 6, same as step 2.

Step 7, pile warp 20 fully raised, pile warp 20 and binder warp 21 raised half way, formingan upper shed. Stutfer warp 22 lowered, forming a lower shed. Wire 23 i; inserted in upper-shed, b'a'ck weft 27 inserted in lower s ed.

Step '8 same as step 2;

Step' '9 same as step 3. Y

Figure 9 produces a out high pile, with low pile formed over the thick or variable face wefts as shown. The low pile is in the same rows as the high pile.

It is thus understood in this weave there are three positions for a particular pile warp end:

(I) It can be selected and raised over the wire.

(2) It can be rejected and raised over the thick or wavy front weft to form low pile.

(3) It can be wholly rejected and carried in the back of the fabric.

It will be evident that in all of these weaves after the fabric has been formed and at a suitable distance beyond the shed the wires are withdrawn transversely. If they are cutting wires they will of course cut the high pile, but the low pile formed directly over the front wefts is uncut.

It will be evident that the form of Figure 1 especially has the advantage of showing the pile at the back to produce an attractive back on the carpet or rug. It also gives some support to the pile from the front wefts when they are thick.

In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the method and fabric shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

1. A pile fabric having at least one pile warp, at least one binder warp, at least one stuifer warp and wefts above and below the stutfer warp interwoven together, the upper wefts varying in thickness, having thick portions between /a and inch in thickness and thin portions between hi and inch in thickness, certain pile warp ends being raised in a high pile substantially above the corresponding upper weft and certain pile warp ends being raised in a low pile directly over the corresponding upper weft.

2. A pile fabric having at least one pile warp, at least one binder warp, at least one stulfer warp and wefts above and below the stufier warp interwoven together, the upper wefts varying in thickness, having thick portions between A; and A inch in thickness and thin portions between A and Vs inch in thickness, certain pile warp ends in each transverse row being raised in high pile substantially above the corresponding upper weft according to a pattern and certain other pile warp ends in the same transverse row being raised in a low pile directly over the corresponding upper weft.

3. A pile fabric having at least one pile warp, at least one binder warp, at least one stufier warp and wefts above and below the stufier warp interwoven together, the upper wefts varying in thickness, having thick portions between A and A inch in thickness and thin portions between A and inch in thickness, all of the pile warp ends in one transverse row being raised in a high pile substantially above the corresponding upper weft and all of the pile warp ends in the next transverse row being raised in a low pile directly over the corresponding upper weft.

4. A pile fabric having at least one pile warp, at least one binder warp, at least one stulfer warp and wefts above and below the stufier warp interwoven together, the upper wefts varying in thickness, having thick portions between Va and A inch in thickness and thin portions between A and 4: inch in thickness, there being at one weft position high pile raised according'to a pattern, other pile warp ends at the same weft position being raised directly over the corresponding upper weft and forming low pile, the binder warp at the corresponding weft position being above the weft and the stuifer warp at that position being below the weft, and having at the next weft position the stutter warp above the weft and all other warps below the weft.

5.' A pile fabric having at least two pile warps, at least one binder'warp, at least one stuffer warp and wefts above and below the stufier warp interwoven together, the upper wefts varying in thickness, having thick portions between and inch in thickness and thin portions between A and inch in thickness, there being at one upper weft position certain ends of one pile warp raised in a high pile according to a pattern, certain ends of the same pile warp raised in a low pile directly over the corresponding upper weft, there being in an adjacent upper weft position certain ends of the other pile warp raised in a high pile according to a pattern and certain ends of the other warp raised in a low pile over the corresponding upper weft and there being in another adjacent upper weft position no pile warp raised over the upper weft.

6. A pile fabric having a plurality of pile warps, at least one binder warp, at least one stutter warp and wefts interwoven together, all of the ends of one pile warp being raised in high pile in certain transverse rows and all of the ends of another pile warp being raised in low pile in adjoining transverse rows directly over face wefts varying in thickness, having thick portions between Vs and M4 inch in thickness and thin portions between and /s inch in thickness.

7. A pile fabric having a plurality of pile warps, at least one binder warp, at least one stufier warp and wefts interwoven together, all of the ends of one pile warp being raised in high pile in certain transverse rows and all of the ends of another pile warp being raised in low pile in adjoining transverse rows directly over face wefts varying in thickness, having thick portions between and inch in thickness and thin portions between A and inch in thickness, and all of the ends of the other pile warp being raised in high pile in other transverse rows.

8. A pile fabric having a [plurality of pile warps, at least one binder warp, at least one stuffer warp and wefts interwoven together, all of the ends of one pile warp being raised in high pile tufts in certain transverse rows, and all of the ends of another pile warp being raised in low pile in the same transverse rows directly over face wefts varying in thickness, having thick portions between Ma and $4 inch in thickness and thin portions between A and inch in thickness.

9. A pile fabric having a plurality of pile warps, at least one binder warp, at least one stutfer warp and wefts interwoven together, all of the ends of one pile warp being raised in high pile tufts in certain transverse rows, and all of the ends of another pile warp being raised in low pile in the same transverse rows directly over face wefts varying in thickness, having thick portions between /8 and inch in thickness and thin portions between A and inch in thickness, and all of the ends of both pile warps being raised in low pile in adjoining transverse rows directly over face wefts varying in thickness, having thick portions between ?/8 and Mt inch in thickness and thin portions between $4 and /s inch in thickness.

10. A pile fabric having a plurality of pile warps, at least one binder warp, at least one stulfer warp and wefts interwoven together, all of the ends of one pile warp being raised in high pile tufts in certain transverse rows, and all of the ends of another pile warp being raised in low pile in the same transverse rows directly over face wefts varying in thickness, having thick portions between A and inch in thickness and thin portions between A and V3 inch in thickness, all of the ends of the other pile warp being raised in high pile tufts in other transverse rows and all of the ends of the one pile warp being raised References Cited in the file 11f .this ;patent UNITED STATES PATENTS- Lister ..TSpt.2f7;192'7 zeospzz S Mostertz ema ls, 1933 Michaelis Apr. 30,4935 Groat 'Mar. 27, 1951 Jackson Nov. 27; 1951 Parlin Aug. 10, 1954 FOREIGN PATENTS" Germany -Jan. 16,1914 Great Britain Mar. 30, 1933 Ar Y. 

